Male external catheter with absorbent and adhesive

ABSTRACT

The invention relates generally to external urinary catheters for males. More specifically, the invention relates to an external urinary catheter that includes an absorbent material to absorb urinary discharge. The absorbent material can be located in either a distal end of a tubular sheath, or in a receptacle that attached to the distal end of the tubular sheath. The tubular sheath of the external urinary catheter can include a tubular sheath of silicone rubber, wherein the sheath has an inner surface and an outer surface, and a layer of adhesive material directly and non-releasably bonded to the inner surface.

PRIORITY

This application is a division of U.S. patent application Ser. No.11/104,388, filed Apr. 12, 2005, now U.S. Pat. No. 8,864,730, which isincorporated by reference in its entirety into this application.

TECHNICAL FIELD

The invention relates generally to external urinary catheters for males.More specifically, the invention relates to an external urinary catheterthat includes an absorbent material to absorb urinary discharge.

BACKGROUND

Urinary incontinence can be a serious problem for men. Many incontinentmen, particularly post prostatectomy patients, leak only small amountsof urine between normal voiding. Generally, male incontinence is handledthrough use of urine collection devices or absorbent pads. Urinecollection devices include what is commonly called a “leg bag.” A legbag generally includes a tube and a large collection bag sized tocollect an amount of urine typically discharged during voiding. The tubeis retained near the urethra and extends to a location where the largecollection bag resides. Often the large collection bag is strapped tothe user's leg; hence the term “leg bag.”

Existing remedies, although suited for individuals who leak asubstantial volume of urine, are not well suited for an incontinent malethat leaks only small volumes of urine between voiding. The existingdevices are big, bulky, and uncomfortable. Other existing devicesocclude leakage of urine, and are also uncomfortable. Some men willforego wearing such devices even though they suffer from urinaryincontinence. Such men, and others using existing devices for thecollection of only small amounts of urine, would benefit from a smaller,less bulky and more comfortable device that collects the small amountsof urine discharged between normal voiding.

Therefore, a need remains for a device that collects small amounts ofurine leaked or discharged from incontinent males that does notnecessarily occlude the leakage of urine and is not highly cumbersome tothe user.

SUMMARY

The present disclosure relates to devices for management of male urinaryincontinence, particularly for collecting small amounts of urinedischarged between normal voiding. The present disclosure furtherrelates to methods associated with the devices, including methods of useand manufacture. In one aspect of the present disclosure, the devicesinclude male external urinary catheters that have an absorbent suitablefor absorbing the small amounts of urine discharged between normalvoiding.

A variety of examples of desirable device features or methods are setforth in part in the description that follows, and in part will beapparent from the description, or may be learned by practicing variousaspects of the disclosure. The aspects of the disclosure may relate toindividual features as well as combinations of features. It is to beunderstood that both the foregoing general description and the followingdetailed description are explanatory only, and are not restrictive ofthe claimed invention.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is an enlarged cross sectional view of an external urinarycatheter of the present invention shown in a pre-use orientation;

FIGS. 2 through 5 are cross sectional views of embodiments of theinvention that have absorbent material in a distal end of the externalurinary catheter;

FIGS. 6 through 8 are cross sectional views of embodiments of theinvention that have absorbent material in a reversibly joined receptacleof the external urinary catheter;

FIGS. 9 and 10 are cross sectional views of embodiments of the inventionthat also include a semi-permeable barrier;

FIG. 11 is a cross sectional view of an embodiment of the invention thathas the absorbent material adhered to an inner surface of a tubularsheath;

FIG. 12 is a cross sectional view of an embodiment of the invention thathas the absorbent material adhered to the inner surface of thereceptacle;

FIG. 13 is a perspective view of the external urinary catheter of FIG. 1shown when the catheter is partially unrolled onto a penis;

FIG. 14 is a perspective view of the external urinary catheter of FIG.13 shown when the catheter is fully unrolled onto the penis;

FIG. 15 is a side view of a mandrel used to form the tubular sheath ofthe external urinary catheter of the present invention;

FIG. 16 is a partial cross-sectional view of the mandrel of FIG. 15shown when partially coated with a silicone coating;

FIG. 17 is a view similar to FIG. 16, but after the mandrel is partiallycoated with an adhesive layer;

FIG. 18 is a view similar to FIG. 17, but after a portion of thesilicone coating and the adhesive layer on the mandrel have beenstripped away;

FIG. 19 is a view similar to FIG. 18, but after a first overcoat layerof silicone rubber solution has been coated on the mandrel over theadhesive layer and silicone coating remaining on the mandrel;

FIG. 20 is a view similar to FIG. 19, but after an application of asecond overcoat layer of a silicone rubber solution to a portion of themandrel;

FIG. 21 is a view similar to FIG. 20, but after a step of curing orvulcanizing the tubular sheath, and showing an upper portion of thetubular sheath of the external urinary catheter rolled up;

FIG. 22 is a schematic illustration of a mechanized system used to coatthe mandrels, as shown in FIGS. 15-21;

FIG. 23 is an enlarged cross-sectional view of the upper portion of theexternal urinary catheter of FIG. 1 in the pre-use orientation;

FIG. 24 is a top plan view of yet another embodiment of an externalurinary catheter of the present invention; and

FIG. 25 is a side view of a portion of the external urinary catheter ofFIG. 24.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

Reference will now be made in detail to various features of the presentdisclosure that are illustrated in the accompanying drawings. Whereverpossible, the same reference numbers will be used throughout thedrawings to refer to the same or like parts.

I. Structural Description, Generally

Referring to FIG. 1, one embodiment of an external urinary catheter 100is illustrated. The external urinary catheter 100 generally includes atubular sheath 110, an adhesive layer 115, and absorbent material 120.

Following manufacture and during pre-use storage, the external urinarycatheter 100 will generally have a pre-use orientation, as shown inFIG. 1. In the pre-use orientation, an upper portion 150 of the tubularsheath 110 is rolled up as shown. The tubular sheath 110 of the catheter100 has an inner surface 112 and an outer surface 114. When the upperportion 150 is rolled up in the pre-use orientation, the inner surface112 contacts the outer surface 114 of the tubular sheath 110.

The adhesive layer 115 of the external urinary catheter 100 is providedon the inner surface 112 of the tubular sheath 110 during manufacture.Typically, the adhesive layer 115 includes a biocompatible adhesive. Abiocompatible adhesive is an adhesive that can contact skin for extendedperiods without irritating or damaging the skin. Typically, the adhesivelayer 115 is non-releasably bonded to a bonding region 152 of the innersurface 112, as will discussed in greater detail hereinafter.“Non-releasably bonded”, “non-releasable adherence”, or “non-releasablecontact” refers to contact that does not permit easy separation of theadhesive layer 115 from the bonding region 152 of the tubular sheath110.

When the external urinary catheter 100 is in a pre-use orientation, theadhesive layer 115 is non-releasably bonded to the bonding region 152 ofthe inner surface 112, and releasably bonded to the outer surface 114 ofthe tubular sheath 110. “Releasably bonded”, “releasable adherence”, or“releasable contact” refers to contact that permits a relatively easyseparation of the adhesive layer 115 from the outer surface 114 of thetubular sheath 110. The adhesive layer 115 releases and separates fromthe outer surface 114 of the tubular sheath 110 when the upper portion150 of the sheath 110 is unrolled, while the adhesive layer 115 remainsnon-releasably adhered to the bonding region 152 of the tubular sheath110.

Still referring to FIG. 1, the absorbent material 120 of the externalurinary catheter generally functions to absorb leaked or dischargedurine. As will be described in greater detail hereinafter, the absorbentmaterial 120 can either be attached to tubular sheath 110 or simplycontained within the tubular sheath 110. In embodiments that simplycontain the absorbent material 120, it is contemplated that theabsorbent material can be replaced or exchanged by the user withoututilizing a different tubular sheath 110.

General examples of suitable absorbent material include, but are notlimited to: cotton fiber, cellulose fiber, absorbent polymers,hydrophilic absorbing power (powders having a chemical structure thathold moisture either inter-molecularly or intra-molecularly), syntheticfibers, and other types of material that absorb urine.

More specific examples of cellulose fibers include wood pulp, stabilizedwood pulp, wood pulp with super absorbent, peat moss board, tissuepaper, or creped wadding. More specific examples of synthetic fibersinclude nonwoven fibers of polypropylene, polyester, nylon,polyethylene, and copolymers thereof. One example of a suitablesynthetic fiber is isotactic polypropylene.

More specific examples of absorbent polymers include polypropylene,polyacrylates such as sodium polyacrylate, and copolymers thereof.Absorbent polymers formed as a foam material can also be used. Such foammaterials can be formed from the water actuation of polymers based oneither toluene diisocyanate (TDI) or methylene diphenyl diisocyanate(MDI), for example. Theses polymers are commercially available under,for example, the trademarks “HYPOL” (TDI) and “HYPOL PLUS” (MDI) fromW.R. Grace & Co., Organic Chemicals Division (Lexington, Mass.). Polymerfoams can also be formed from polyurethanes or polyolefins.

The external urinary catheter 100 of the present disclosure may includevarious volumes or amounts of the absorbent material 120. Generallyspeaking, the amount of absorbent material 120 used can be described byan actual volume of the absorbent, or by the volume of urine absorbed bythe material. The amount of absorbent material 120 included depends onthe type of the absorbent material and the level of urinary dischargefor which the catheter 100 is designed. For example, the amount ofabsorbent material 120 used for men that have higher levels of urinarydischarge will be greater than the amount used for men that have lowerlevels of urinary discharge.

In general, the absorbent material 120 functions to absorb urinecollected in the tubular sheath 110. In the embodiment shown in FIG. 1,the absorbent material 120 is generally located in a distal end 116 ofthe tubular sheath 110. There are a number of different configurationsof the tubular sheaths 110 in which absorbent material 120 can begenerally located in the distal end 116. Examples of such alternativeembodiments are shown in FIGS. 2-5.

Referring now to FIGS. 2-5, the distal end 116 of each of the tubularsheaths 110 has a different configuration. The different configurationsof FIGS. 2-5 are only exemplary configurations; and other configurationsare contemplated.

Referring specifically to FIG. 2, the distal end 116 of the tubularsheath 110 has a generally square shape with a cross-sectional dimensionD1. The cross-sectional dimension D1 is approximately equal to adiameter D2 of a main portion 154 of the tubular sheath 110. In analternative embodiment, the cross-sectional dimension D1 can be largeror smaller than the diameter D2 of the remainder of the tubular sheath110.

In FIG. 3, the distal end 116 of the tubular sheath 110 has a generallyrounded shape with a maximum diameter D3. The maximum diameter D3 isapproximately the same as that of the main portion 154 of the tubularsheath 110. In FIG. 4, the distal end 116 has a generally round shapewith a maximum diameter D4. The maximum diameter D4 is greater than thatof the main portion 154 of the tubular sheath 110.

In FIG. 5, the distal end 116 has a generally round shape with a maximumdiameter D5 that is also greater than the diameter D2 of the mainportion 154 of the tubular sheath 110. However, in FIG. 5, the distalend 116 includes a necked portion 156 that reduces in diameter prior toexpanding to the maximum diameter D5. In an alternative embodiment, thetubular sheath 110 can include a necked portion that expands to amaximum diameter D5 that is less than the diameter D2 of the mainportion 154. It should also be understood that any combinations of theseand other distal end constructions and shapes could be utilized. Forexample, the distal end 116 can have a necked portion, and include agenerally square shape with a dimension greater than or less than themain portion 154 of the tubular sheath 110.

Referring now to FIGS. 6-8, in alternative embodiments, the absorbentmaterial 120 can be located in a receptacle 122 (e.g. a pouch orcartridge). (See also FIG. 24.) Typically, the receptacle 122 isinterconnected to the distal end 116 of the tubular sheath 110 by ajoining assembly 124.

The receptacle 122 can be fashioned from a material that is one or moreof pliable, durable, collapsible, and inexpensive. For example, thereceptacle 122 can be pliable so that the catheter 100 is more malleableand comfortable for a user. The receptacle 122 can be durable to limitthe possibility of the receptacle 122 being pierced or ruptured. Thereceptacle 122 can be inexpensive so that the receptacle 122 can bereplaced whenever appropriate without excessive cost. Examples ofsuitable materials that can be used to manufacture the receptacle 122include, for example, polyvinyl chloride (PVC), polyurethane, blockcopolymers such as kraton, high density polyethylene, low densitypolyethylene, and silicone rubber. As can be understood, the receptacle122 is in certain embodiments waterproof (i.e., not permeable to waterover the length of time that the receptacle will remain in the user'sundergarment). The material can have a waterproof quality, or awaterproofing material can be applied during the manufacture of thereceptacle 122.

Generally, the thickness of receptacle 122 (i.e., the dimension thatwould be shown in a side view of FIG. 6-8) varies depending on the typeof material used, and the type and amount of absorbent material 120used. Typically, the thickness of receptacle 122, including theabsorbent material 120, ranges from about 0.125 inches to about 1.50inches; more typically between about 0.125 inches and 0.750 inches.Preferably, the thickness of the receptacle 122 is sized to becomfortable and concealable.

The capacity of the receptacle 122 varies depending on the level ofurinary discharge for which the specific embodiment is designed.Embodiments designed for higher levels of urinary discharge will havereceptacles 122 with a higher capacity, while those designed for lowerlevels of urinary discharge will have receptacles 122 with a lowercapacity. The capacity of the receptacles 122 can be smaller than a legbag and suitable for receiving discharge between voiding. Typically, thereceptacle 122 has a capacity or volume V from about 25 mL to about 100mL. Generally speaking, if the receptacle 122 is designed for higherlevels of urinary discharge, the receptacle has a volume V of about 40to 100 mL. If the receptacle 122 is designed for lower levels of urinarydischarge, the receptacle has a volume V of about 25 to 35 mL.

The shape of receptacle 122 can vary. Exemplary configurations of thereceptacle 122 are illustrated in FIGS. 6-8. As shown, the receptacle122 can have virtually any shape, including a generally round shape(FIGS. 6 and 7) and a generally square shape (FIG. 8).

Embodiments that include the receptacle 122 can be designed so thatreceptacles of variable capacity can be used interchangeably. Thisfeature allows a user to vary the capacity of the external urinarycatheter 100 based on a personal level of urinary discharge, which mayor may not vary. For example, in one embodiment, a kit may be providedto a user. The kit may include a tubular sheath 110 along with an arrayof receptacles 122. Each receptacle provided would include a differentamount of absorbent material contained within the receptacle. This wouldpermit the user to adjust the capacity of the external urinary catheter100 according to the daily needs of the user.

In use, discharged urine flows from the sheath 110, through the joiningassembly 124, and into the receptacle 122. The joining assembly 124 ofthe external urinary catheter 100 functions to reversibly join thereceptacle 122 to the distal end 116 of the tubular sheath 110. What ismeant by “reversibly join” is that the receptacle 112 sealingly attachesto the tubular sheath 110, yet is detachable or removable from thesheath without causing damage to the sheath.

The joining assembly 124 is sized and constructed such that thereceptacle 122 is located a distance near the distal end 116 of thetubular sheath 110, as opposed to a leg bag which is located a distanceaway from the tubular sheath 110. Typically, the receptacle 122 islocated in relation to the tubular sheath 110 such that the entirecatheter 100, including the receptacle 122, is located at and within thepelvic region of the user. That is, the tubular sheath 110, the joiningassembly 124, and the receptacle 122 can all fit within a user'sundergarment at the urinary area. The user is thereby not encumberedwith routing tubes through the undergarment to locations away from theurinary area, such as is required by conventional leg bags, for example.In the illustrated embodiment, the receptacle 122 is located a distanceD6 (e.g. FIG. 8) of about one inch to about three inches from the distalend 116 of the tubular sheath 110.

In the embodiment of FIG. 6, the joining assembly 124 includes a femaleconnector 158 extending from the distal end 116 of the tubular sheath110, and a male connector 160 extending from the receptacle 122. In theembodiment of FIG. 7, the female connector 158 of the joining assembly124 extends from the receptacle 122, and the male connector 160 extendsfrom the distal end 116 of the tubular sheath 110. In each embodiment,the male connector 160 fits within the female connector 158 so that thetubular sheath 110 is reversibly joined to the receptacle 122.

In another embodiment, the joining assembly 124 can include a lock andunlock feature so that receptacle 122 is more securely reversibly joinedto tubular sheath 110. In yet another embodiment, the joining assembly124 functions like or includes a luer lock type assembly. As shown inFIGS. 6-8, the size of joining assembly 124 can vary. For example, inFIG. 7, the joining assembly 124 is larger than the joining assembliesshown in FIGS. 6 and 8. In an embodiment, the joining assembly 124 islarge enough so that urine flow into the receptacle 122 is notrestricted.

Referring now to FIGS. 24 and 25, another alternative embodiment of theexternal urinary catheter 100 is illustrated. Similar to some of theprevious embodiments, the tubular sheath 110 of this embodiment isinterconnected to the receptacle 122 via the joining assembly 124.

As shown in FIG. 24, the distal end 116 of the tubular sheath 110defines an opening 166 that receives the joining assembly 124. Thejoining assembly 124 provides fluid communication between the tubularsheath 110 and the receptacle 122. The opening 166 is located in thetapering or necked portion 156 of the tubular sheath.

The joining assembly 124 in the illustrated embodiment includes a hollowfitting 130 and a tube member 140. In an embodiment, each of the hollowfitting 130 and the tube member 140 of the joining assembly 124 is sizedso that urine flow into the receptacle 122 is not restricted.

The hollow fitting 130 has first and second ends 132, 134. Each of thefirst and second ends 132, 134 is a male fitting end. The first malefitting end 132 is sized and constructed for receipt within the opening166 formed in the distal end 116 of the tubular sheath 110. In theillustrated embodiment, the first male fitting end 132 includes ridges138 that taper to ease insertion and removal of the fitting 130 into andfrom the opening 166. Other embodiments may include a first end 132 thatcontinuously tapers without ridges, or that has a straight fittingconstruction.

The second male fitting end 134 is received within a first end 142 ofthe tube member 140. In the illustrated embodiment, the second malefitting end 134 is secured within the first end 142 of the tube member140 by an adhesive or other securing material or construction. In theillustrated embodiment, the second male fitting end 134 is a straightfitting end. Other embodiments may include a second end 134 thatcontinuously tapers or includes ridges.

A second end 144 of the tube member is positioned within an opening 90formed in the receptacle. In the illustrated embodiment, the second end144 of the tube member 140 is secured within the opening 90 of thereceptacle 122 by an adhesive or other securing material orconstruction.

In the embodiment shown in FIGS. 24 and 25, the receptacle 122 isconstructed from a material that is pliable and durable, such as PVC,for example. In particular, first and second sheets or plies 168, 170 ofthe material are joined together to form an interior 172 for receipt ofthe absorbent material 120. In one embodiment, the two plies may be sewntogether along a seam 102, or adhered together along the seam. The PVCreceptacle 122 also has sufficient pliability so that the catheter 100is more malleable and more comfortable for a user. In addition, the PVCreceptacle 122 is durable to limit the possibility of the receptacle 122being pierced or ruptured. Further, the PVC receptacle has moistureimpermeable qualities that contain moisture absorbed by the absorbentmaterial 120 within the interior 172 of the receptacle 122 so that theexterior of the receptacle 122 remains dry.

As shown in FIGS. 24 and 25, the receptacle 122 generally has a width W,a height H, and a thickness T, although the disclosed principles can beapplied in a variety of sizes and applications. The width W of thereceptacle 122 can be, for example, between 1.5 and 5.0 inches orbetween about 2.0 and 3.0 inches. The height H of the receptacle 122 canbe, for example, between 2.0 inches and 6.0 inches or between about 3.0and 4.0 inches. The thickness T of the receptacle 122 is generallybetween 0.125 inches and 1.50 inches, depending upon the type ofabsorbent material 120 used. In an embodiment, the thickness T isbetween about 0.5 and 1.0 inches. Further, the distance D6 (see FIG. 6)between the receptacle 122 and the distal end 116 of the tubular sheath110 when assembled (not shown) can be between 2.0 inches and 6.0 inches;e.g., between about 3.5 and 4.5 inches.

Each of the width W, the height H, the thickness T, and the distance D6are sized and dimensioned such that the receptacle 122 conveniently fitswithin the undergarment of the user. That is, the receptacle 122 issized so that the entire catheter 100 fits within the user's underwear,and does not required that the receptacle be attached or located at alocation away from the pelvic area of the user. Accordingly, the PVCmaterial of the receptacle 122 is also chosen to be comfortable againstthe user's skin. For example, the exterior of the receptacle 122 can beflocked with cotton or synthetic flocking, or embossed. As previouslydiscussed, the shape of receptacle 122 can vary. In the embodiment ofFIGS. 24 and 25, the receptacle 122 has a rectangular configuration,although any shape that comfortably fits an average-sized male can beused.

At the same time, the receptacle 122 is sized to provide a urineabsorbing capacity depending on the level of urinary discharge betweennormal voiding. As previously described in relation to the otherembodiments, the capacity of the receptacle 122 of FIG. 24 can besmaller than a leg bag and suitable for receiving discharge betweenvoiding. The width W, height H, and thickness T of the receptacle 122defines a volume associated with the receptacle 122. The capacity of thereceptacle 122 is a function of the volume and the type of absorbentmaterial 120 used. In an embodiment, the volume of the receptacle 122 isbetween 1.0 cubic inch and 5.0 cubic inches. In one embodiment, theabsorbent material 120 is cellulose fiber. In providing cellulose fiberabsorbent material in the volume of between about 3.0 and 4.0 cubicinches, the receptacle 122 has a capacity to contain between about 45and 60 mL of urine. Because the receptacle 122 is sized to fit withinthe user's pelvic region, (i.e., within the user's undergarment) thecapacity of the receptacle 122 is typically no more than about 100.0 mL.

Similar to the previous embodiments, the embodiment of FIG. 24 isdesigned so that the receptacle 122 can be interchanged. This featureallows a user to vary the capacity of the external urinary catheter 100based on a personal level of urinary discharge, which may or may notvary. For example, a user may interchange a first receptacle with asecond receptacle having a different amount of absorbent material or adifferent type of absorbent material to adjust the capacity of theexternal urinary catheter 100.

The receptacle 122 is also interchangeable so that a user can replace afilled or used receptacle with a new receptacle as needed. For example,during use of the catheter 100 embodiment of FIG. 24, urine dischargedinto the sheath 110 flows through the joining assembly 124 and into thereceptacle 122. When the receptacle 122 has filled, the user detachesthe filled receptacle by removing the first end 132 of the fitting 130from the opening 166 in the tubular sheath 110. The tubular sheath 110remains in position on the penis. A new receptacle is then attached tothe distal end 116 of the tubular sheath.

The joining assembly 124 of the external urinary catheter 100 functionsto reversibly join the receptacle 122 to the distal end 116 of thetubular sheath 110. In the embodiment of FIG. 24, the joining assembly124 attaches and detaches from the tubular sheath 110 (i.e., the joiningassembly 124 is removed or detached along with the receptacle 122). Inan alternative embodiment, the catheter 100 can be constructed such thatthe receptacle 122 attaches and detaches from the joining assembly 124(i.e., only the receptacle 122 is removed or detached).

The receptacle 122 can also be disposable. The user may simply throwaway the receptacle when the receptacle has been filled. In alternativeembodiments, the receptacle 122 may be recycled. That is, the receptaclecan be configured to provide access to the absorbent material 120 sothat used absorbent material can be removed and replaced with newmaterial, and the receptacle 122 reused.

Various alternative embodiments including other features can bepracticed in accord with the principles disclosed. For example, theexternal urinary catheter 100 may include more than one type ofabsorbent material 120. For instance, a synthetic fiber such aspolypropylene, polyester, nylon, polyethylene, or copolymers thereof canbe spunbound to create a coverstock for another absorbent. A coverstockfunctions to provide a semi-permeable membrane or barrier that allowsmoisture to pass through that barrier so that the moisture is absorbedby another absorbent material enclosed within the barrier. Use of acoverstock provides a number of advantages, including keeping the skinof the user more dry, and retaining the absorbent material 102 in aparticular location, such as a distal end 116 of the tubular sheath 110.Suitable examples of synthetic fibers that can be spunbound to formcoverstock include polyester and polypropylene.

Referring now to the external urinary catheters 100 of FIGS. 9 and 10,two embodiments of a coverstock or semi-permeable barrier 126 areillustrated. In the embodiment of FIG. 9, the semi-permeable barrier 126is located adjacent to the distal end 116 of the tubular sheath 110. Inthe embodiment of FIG. 10, the semi-permeable barrier 126 is in thejoining assembly 124.

The semi-permeable barrier 126 functions to allow urine to pass into theabsorbent material 120, but does not allow the absorbent material 120 tomigrate through to the main portion 154 of the tubular sheath 110.Alternatively, or in addition, the semi-permeable barrier 126 canfunction to allow urine to pass through into the volume V containing theabsorbent material 120, but does not allow urine to pass out of thevolume V. In an embodiments in which the absorbent material 120 iscompletely contained or surrounded by the barrier 126, the barrier 126and the absorbent material 120 can be replaced or exchanged by the userwithout utilizing another tubular sheath 110. For example, as shown inFIGS. 13 and 14, the barrier 126 and absorbent material 120 can beprovided in the form of a packet 118. The packet 118 can be replaced andexchanged without utilizing another tubular sheath 110. It is to beunderstood that the semi-permeable barrier can be incorporated into anyof the embodiments shown, and in combination with any other featuresdescribed.

Another alternative embodiment including another feature that can bepracticed in accord with the principles disclosed is illustrated in FIG.11. In this embodiment the absorbent material 120 of the externalurinary catheter 100 is adhered to the inner surface 112 of the tubularsheath 110. Adhering the absorbent material 120 to the inner surface 112prevents the absorbent material 120 from migrating within the tubularsheath 110. Methods of adhering the absorbent material 120 to the innersurface 112 of the tubular sheath 110 vary depending on the compositionof the absorbent material 120. The absorbent material 120 can also beadhered to the inner surface of the receptacle 122, as shown in FIG. 12.It is to be understood that adhering the material to an inner surfacecan be incorporated into any of the embodiments shown, and incombination with any other features described.

II. Method of Use

The external urinary catheter 100 is typically worn by users thatdischarge relatively small amounts of urine between normal voiding, ascompared to users that discharge an amount that necessitates a leg bag.Referring to FIGS. 13 and 14, in use, a user, or perhaps a health careprofessional, engages a tip 31 of a penis 30 with the external urinarycatheter 100 in the pre-use orientation (shown in FIG. 1). Inparticular, the distal end 116 of the tubular sheath 110 is applied tothe tip 31 of the penis 30. The upper portion 150 of the tubular sheath110 is then unrolled using moderate force to press the rolled up portionof the upper portion 150 in a direction away from the tip 31 of thepenis 30. This can generally be accomplished by pressing on the rolledupper portion 150 with one's thumb and forefinger (not shown).

As the upper portion 150 unrolls, the adhesive layer 115 releases fromthe outer surface 114 of the tubular sheath 110. In an embodiment, thereleasability characteristics are such that the upper portion 150 isrelatively easy to unroll onto the penis 30. As the adhesive layer 115comes into contact with an outer surface 32 of the penis 30, theadhesive layer 15 adheres to the outer surface 32. This secures theexternal urinary catheter 100 to the penis 30. In an embodiment, theadhesive layer 115 seals the tubular sheath 110 to the penis 30 suchthat leakage above the area where the adhesive layer 115 contacts theouter surface 32 of the penis 30 is prevented. The external urinarycatheter 100 secures to the user only at the location where the adhesivelayer 115 contacts the outer surface 32 of the penis. No other belts,straps, garments, or coupling/attaching devices are necessary. Thecatheter 100 of the present invention thereby provides a morecomfortable solution to incontinence, and is not highly cumbersome orbulky for the user.

The external urinary catheter 100 can be removed from the penis 30 bypulling the upper portion 150 of the tubular sheath 110 away from thepenis 30 and down over the outer surface 114. Removal can beaccomplished in any manner that accommodates the comfort of the patient.It will be appreciated that one appropriate method of removing thecatheter 100 is to roll the upper portion 150 up again so that thecatheter 100 returns to generally the same orientation as that shown inFIG. 1. When removing the catheter 100, the adhesive layer 115 releasesthe outer surface of the penis 30, and the catheter 100 can be removedfrom the penis 30 with relative ease.

Generally speaking, the external urinary catheter 100 can be worn forvariable amounts of time depending on the user, the capacity for whichthe device is designed, and the amount of urinary discharge the user isexperiencing. For example, the external urinary catheter 100 can be wornfor certain defined periods of time, until the catheter begins to feeluncomfortable, until the absorbent has reached an absorbance capacity,or until the user removes the catheter to void.

Depending on the specific absorbent material 120 utilized, the catheter100 may exhibit altered characteristics when the material has absorbedan amount of urine. Examples of such altered characteristics include anincrease in the weight of the catheter 100 and a change in theflexibility of the portion of the catheter 100 that contains theabsorbent material 120. In certain embodiments, the absorbent materialcan change color to indicate that material is saturated with urine.Changes such as these and others can also be used by the wearer todetermine when the catheter 100 should be removed and/or replaced.

In addition, in embodiments having a detachable receptacle 122 (e.g.,FIG. 24), the tubular sheath 110 can be worn throughout the day, notonly between voiding. In particular, the receptacle 122 can be detachedwhen the user needs to void. The user can then void through the open end166 of the tubular sheath 110, and then reattach the receptacle 122 orreattach a replacement receptacle to the same tubular sheath 110.

III. Method of Manufacturing

As described herein below, the tubular sheath 110 can be made bycombining two or more layers of a silicone rubber solution or ofseparate silicone rubber solutions. Once the silicone rubber solutionsare dried and cured in a vulcanizing process, the respective siliconerubber solution coatings combine to form a single unitary tubular sheathwithout separate layers. It will be appreciated that any silicone rubbersolution used to form silicone rubber products of one type or anothermay be used to form the silicone rubber sheath of the present invention.The vulcanizing process may be either a heat process, a catalyzedprocess employing a catalyzing agent or agents, a combination of thetwo, or any other suitable vulcanizing process known in the art.

Referring now to FIGS. 15-22, a suitable method of making an externalurinary catheter 100 of the present invention includes a series of stepsdesigned to coat a mandrel 20. The mandrel 20 has a generallycylindrical shape, which may narrow or taper at a lower end 22 (FIG.15). In one embodiment, the lower end 22 of mandrel 20 may include alarger diameter than that of the remaining mandrel 20. The mandrel 20having a larger lower end diameter may be utilized to form a bulbousportion 162 at the distal end 116 of the tubular sheath 110, such asshown in FIG. 4. Alternatively, the lower end 22 of mandrel 20 may beconfigured to provide the embodiments shown in FIGS. 2, 3, and 5. Incertain embodiments, either the external surfaces 164 of the mandrel 20are coated with Teflon®, or the mandrel 20 is made of Teflon®. A tip(not shown) for forming male or female connectors 158, 160 (FIGS. 6 and7) of the joining assembly 124 can be coupled to the lower end 22 of themandrel 20.

In an embodiment, depicted in FIG. 22, a series of mandrels 20 areattached to a pallet 23 so that numerous external urinary catheters 100can be mass-produced. This can be accomplished by coating each of themandrels 20 in a series of coating steps. The coating steps includedipping each of the mandrels 20, e.g., in unison, in a series of diptanks 80 a-e that are raised up to a precise level calculated toaccomplish a specific task. It will be appreciated that a series (notshown) of pallets can also be employed so that a continuous mechanizedproduction operation can be developed to mass-produce catheters 100. Thepallet 23 or a series of pallets (not shown) are advanced by amechanized advancing system 88. It will be appreciated that any knownmechanization system for advancing the pallet 23 or pallets can be used.

Referring now to FIGS. 16 and 22, in one method of manufacture, a firstportion 24 of the mandrel 20 is coated with a silicone coating 40. Thefirst portion 24 of the mandrel 20 is defined as the area of the mandrelbetween dashed lines A and B illustrated in FIG. 16. To create thesilicone coating 40, the pallet 23 of mandrels 20 is dipped into a firstdip tank 80 a containing a fluid silicone release agent 81, e.g., apolydimethylsiloxane fluid (Dow Corning 360 Medical Fluid from DowCorning, Inc., Midland, Mich. 48360) having a viscosity of 12,500centistokes, diluted about 1:25 in hexamethyldisiloxane. The fluidsilicone release agent 81 forms the silicone coating 40. In order toensure that the first portion 24 (FIGS. 16-18) of the mandrel 20 iscompletely coated with the silicone coating 40, the pallet 23 to whichthe mandrels 20 are attached is centered over the first dip tank 80 aand the dip tank 80 a is raised a calculated distance, as shown. Thedistance is calculated such that the mandrel 20 is submersed within therelease agent 81 to a designated level corresponding to the dashed lineA. At the designated level, the entire first portion 24 of mandrel 20 issubmersed. After the first portion 24 is fully submersed, the first diptank 80 a is lowered and the silicone coating 40 is permitted to dry(FIG. 16).

Referring now to FIGS. 17 and 22, the pallet 23 is then advanced to asecond dip tank 80 b containing adhesive material or fluid 82. Theadhesive material 82 bonds to unvulcanized silicone rubber during avulcanizing process. The adhesive material 82 can include a suitablepolymeric adhesive, such as a suitable copolymer of acrylic acid esterswith vinylacetate, or cross linking pressure sensitive adhesive, forinstance. One example of an adhesive that can be used is Gelva MAS 788manufacture by Solutia Inc. (St. Louis Mo.). The second dip tank 80 b israised a distance (not shown) calculated to dip the mandrel 20 into theadhesive fluid 84 in the second dip tank 80 b so that the entire firstportion 24 of the mandrel 20 between the lines designated A and B iscoated by the adhesive fluid 82. As shown in FIG. 17, the adhesive fluid82 forms the adhesive layer 115, which is disposed over the siliconecoating 40. The second dip tank 80 b is then lowered, and the adhesivelayer 115 allowed to dry for a period of time.

Referring now to FIGS. 18 and 22, the pallet 23 is then advanced to athird dip tank 80 c containing a solvent 83, e.g., trichloroethane(trichlor 1,1,1) or xylene. The solvent 83 strips or removes theadhesive layer 115 and the silicone coating 40 from the mandrel 20. Inthis step, the dip tank 80 c is raised a distance (not shown) calculatedto dip the mandrel 20 into the solvent 83 up to the line on the mandrel20 designated B so that the adhesive layer 115 and the silicone fluidcoating 40 which coat a second portion 26 of the mandrel 20 is stripped.The second portion 26 of the mandrel 20 is defined as the area of themandrel below the line designated B, and proximate the lower end 22 ofthe mandrel 20. In some methods, the tank 80 c may be lowered and raisedseveral times to provide a rapid stripping action. The pallet 23 canalso be advanced to a new dip tank (not shown) having a second solvent(not shown) to further assist in stripping the second portion 26 of themandrel 20. In some embodiments, a vibrator (not shown) is connected tothe pallet 23 or the mandrel 20 to vibrate the mandrel 20 and speed theremoval of the adhesive coating 115. In other embodiments, an ultrasoniccleaning system (not shown) is incorporated into the dip tank 80 c.

In some methods, a further step can be added at this point in themanufacturing process. This step involves shaping the lower end 22 ofmandrel 20 by selectively coating the lower end 22 with an agent thatbuildups the lower end 22. Shaping the lower end 22 of the mandrel 20provides the shaped distal end 116 configurations of the catheter 100previously disclosed. The agent can be the same or similar to that ofthe mandrel release agent 81 utilized previously.

In continuing the manufacture of the catheter 100, the mandrel 20 isadvanced on the pallet 23 to a fourth dip tank 80 d containing anunvulcanized silicone rubber solution 84 which can be a disiloxanesolvent, e.g., a hexamethyldisiloxane solvent. The disiloxane solvent issuitable because the disiloxane solvent does not destroy the integrityof the adhesive layer 1715 that remains on the first portion 24 of themandrel 20. When the mandrel 20 is dipped into the silicone rubbersolution 84 in the fourth dip tank 80 d, the silicone rubber solution 84coats the mandrel 20 and overcoats the silicone coating 40 and theadhesive layer 115. This overcoating forms a first overcoat layer 46 asshown in FIG. 19. If the shaping step was performed, the first overcoatlayer 46 will have a shaped region, such as an enlarged region, thateventually becomes the distal end 116 of the tubular sheath 110. Thefourth dip tank 80 d is then lowered, and the overcoat layer 46 isallowed to dry for a period of time.

Referring now to FIGS. 20 and 22, the pallet 23 is then advanced to afifth dip tank 80 e containing an additional silicone rubber solution88. The additional silicone rubber solution 88 can have a greaterconcentration of silicone rubber than the first overcoat layer 46. Thesolvent may also be varied. The dip tank 80 e is raised and the mandrel20 is dipped into the dip tank 80 e to a level just below the linedesignated B so as to add an additional thickness proximate the lowerend 22 of the mandrel 20. This forms a final overcoat layer 48 over thefirst overcoat layer 46. The dip tank 80 e is then lowered and the finalovercoat layer 48 is allowed to air dry so that the solvent in thesilicone rubber overcoat layer 46 evaporates. It will be appreciatedthat additional dip tanks may be provided for additional dipping steps.

In one embodiment, the first overcoat layer 46 has a generally uniformthickness through out the construction of the sheath 110. The thicknessis typically between about 0.002 and 0.010 inches; e.g., between about0.003 and 0.008 inches. The final overcoat layer 48 provides additionalthickness in the proximal region 116 of the sheath 110. The thickness atthe distal end 116 is between 0.020 to 0.080 inches; e.g., between about0.030 to 0.060 inches.

In an embodiment of the method, the final overcoat layer 48 isvulcanized or cured in an oven (not shown) at an elevated temperature,e.g., about 205° F. It will be appreciated that the temperature ismaintained at a level below the boiling point of the solvents of thesilicone rubber solutions to prevent the formation of bubbles in thesilicone rubber caused by evaporation or the boiling off of thesolvents. Furthermore, it will also be appreciated that other siliconerubber systems that are catalyzed without heat may also be used toprovide a vulcanizing system resulting in a vulcanized silicone rubberelastomeric construction 50.

Once the silicone rubber has been vulcanized, the tubular sheath 110 isformed. The tubular sheath 110 is permitted to cool. When cooled, theupper portion 150 of the tubular sheath is rolled from a top 25 of themandrel 20 (FIG. 21) so that the inner surface 112 (FIG. 23) of thetubular sheath 110 rolls up onto the outer surface 114 of the tubularsheath. In the process of rolling the tubular sheath 110, the adhesivelayer 115, which has now been integrally bonded with the silicone rubberduring the vulcanizing process, comes into contact with the outersurface 114 of the tubular sheath 110.

Referring to FIG. 23, when the catheter 100 is fully rolled up into itspre-use orientation (as shown in FIG. 1), the catheter 100 includes thesingle tubular sheath 110 (FIG. 1) having a unitary construction made ofsilicone rubber with an adhesive layer 115 integrally bonded to thetubular sheath 110. The adhesive layer 115 is interposed between theinner surface 112 and the outer surface 114 of the sheath 110. Theadhesive layer 115 is integrally bonded to the inner surface 112 as aresult of cross-linking between constituents in the adhesive layer 115and constituents in the unvulcanized silicone rubber of the overcoatlayer 46 during the vulcanizing process. The adhesive layer 115 willnot, however, irreversibly adhere or bond to any of the vulcanizedsilicone rubber surfaces with which the adhesive contacts after thevulcanizing process. The adhesive layer 115 does contact the outersurface 114, but any adherence to the outer surface 114 is limited toreleasable adherence.

In particular, when the upper portion 150 of the tubular sheath isrolled up, trace amounts of the silicone coating 40 adhere to theadhesive layer 115, and the remaining portion of the silicone coating 40stays on the mandrel 20. The trace amounts of silicone coating 40 thatadhere to the adhesive strip are absorbed by the outer surface 114 ofthe tubular sheath 110 when the coating 40 comes into contact with theouter surface 114.

It is to be appreciated that it is important that the trace amounts ofsilicone fluid adhering to the adhesive layer 115 are absorbed by theouter surface 114, because if not absorbed, the coating 40 couldinterfere with the adherence of the adhesive layer 115 with the penis30. It will also be appreciated that the silicone coating 40 is just oneof many mandrel release agents which can be used to coat the mandrel 20.Other agents that prevent making removal of the adhesive layer 115 fromthe mandrel 20 overly difficult can also be used.

The adhesive layer 115 is selected for its ability to bond with thesilicone rubber during the vulcanized process and for its lack ofadherence when the layer 115 comes into contact with vulcanized siliconerubber after the vulcanizing process. It will be appreciated that anybiocompatible adhesive which will cross-link with silicone rubber duringthe vulcanizing process will be a suitable adhesive so long as thebiocompatible adhesive will releasably adhere to new silicone rubbersurfaces with which the biocompatible adhesive comes into contact afterthe adhesive is bonded to the inner surface of a silicone rubber sheathduring the vulcanizing process.

Inclusion of the absorbent material 120 occurs after the above formationof the tubular sheath 110. The specific method of providing or includingthe absorbent material 120 depends on the specific type of the absorbentmaterial 120 used, and the specific arrangement. For example, in theembodiments having the absorbent material 120 located in the distal end116 of the sheath 110, the absorbent material 12 is typically placed ator adjacent to an enclosed tip 53 (FIG. 21) of the sheath 110. Forinstance, if the absorbent material 120 is hydrophilic powder, thematerial can simply be introduced into the tubular sheath 110, anddirected towards the enclosed tip 53 at the distal end 116 of the sheath110. If the hydrophilic powder is to be adhered to the inner surface 112of the tubular sheath 110, a suitable adhesive, such as Gelva Mas 788,for example, can be applied to the desired portion of the tubular sheath110 adjacent the enclosed tip 53 before the powder is introduced intothe tubular sheath 110.

In the embodiments having the absorbent material 120 located in thereceptacle 122, the enclosed tip 53 of the tubular sheath 110 is removedto provide the opening 166 (FIG. 24) at the distal end 116. Theabsorbent material 12 is disposed in the receptacle 122, and thereceptacle is interconnected to the opening 166 at the distal end 116via the joining assembly 124.

The above specification provides a complete description of theinvention. Since many embodiments of the invention can be made withoutdeparting from the spirit and scope of the invention, certain aspects ofthe invention reside in the claims hereinafter appended.

We claim:
 1. An external urinary catheter, comprising: a tubular sheathincluding a closed distal end and an open proximal end; a layer ofadhesive material non-releasably bonded to a portion of an inner surfaceof the tubular sheath; and an absorbent material positioned distal tothe layer of adhesive material wherein the absorbent material iscontained within and surrounded by a semi-permeable coverstock.
 2. Theexternal urinary catheter according to claim 1, wherein the tubularsheath is formed of silicone rubber.
 3. The external urinary catheteraccording to claim 1, wherein the inner surface is rolled onto an outersurface of the tubular sheath in a storage configuration, the adhesivematerial releasably contacting the outer surface.
 4. The externalurinary catheter according to claim 1, wherein the distal end of thetubular sheath has an end dimension that is different than a diameter ofthe proximal end.
 5. The external urinary catheter according to claim 1,wherein the distal end of the tubular sheath has an end dimension thatis greater than a diameter of the proximal end.
 6. The external urinarycatheter according to claim 1, wherein the absorbent material isisolated from an adjacent section of the tubular sheath by asemi-permeable barrier.
 7. The external urinary catheter according toclaim 6, wherein the semi-permeable barrier comprises a spunboundsynthetic fiber coverstock.
 8. The external urinary catheter accordingto claim 1, wherein the coverstock is a spunbound synthetic fiberselected from the group consisting of polyester and polypropylene. 9.The external urinary catheter according to claim 1, wherein theabsorbent material is positioned in the closed distal end of the tubularsheath.
 10. The external urinary catheter according to claim 1, whereinthe absorbent material includes cellulose fiber.
 11. An external urinarycatheter, comprising: a tubular sheath including a closed distal end andan open proximal end; a layer of adhesive material non-releasably bondedto a portion of an inner surface of the tubular sheath; an absorbentmaterial positioned distal to the layer of adhesive material; and areceptacle detachably interconnected to the distal end of the tubularsheath, the receptacle defining an interior in which urinary dischargeis collected, the absorbent material positioned in the receptacle,wherein the absorbent material is contained within and surrounded by asemi-permeable coverstock.
 12. The external urinary catheter accordingto claim 11, wherein the receptacle is configured to reside within auser's pelvic region when the catheter is worn.
 13. The external urinarycatheter according to claim 11, further comprising a joining assemblypositioned between the distal end of the tubular sheath and thereceptacle, the joining assembly providing fluid communication betweenthe tubular sheath and the receptacle.
 14. The external urinary catheteraccording to claim 11, wherein the interior has a volume sized tocollect no more than 50 mL of urine.